Reactor for circuit containing semiconductor device

Apparatus and method for effectively decreasing current spike, ringing, and electromagnetic noise in a circuit containing a semiconductor device when a voltage applied to the semiconductor is inverted. The core of the reactor is made of an amorphous magnetic alloy having a magnetic flux density of not less than 6 kilogauss at an external magnetic field of 1 oersted, a coercive force of not more than 0.5 oersted, and a squareness ratio of not less than 0.8 when a frequency is set to be 100 kilohertz. The reactor includes the core having a through hole and conductor wound around the core through the through hole. The core is insulated from the conductor.

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Description
BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates to apparatus and method for using a reactor in a circuit containing a semiconductor device.

II. Description of the Prior Art

In general, when the polarity of a voltage applied to a semiconductor device such as a diode is abruptly inverted, the diode temporarily loses its initial function, so that a reverse current flows therethrough. Although the diode recovers its initial function after a short period of time (recovery time), the diode may break down if the reverse current (i.e., a spike current) is large. Furthermore, when resonant elements such as a coil and a capacitor are used in a circuit in which a current spike occurs, the current spike results in ringing for a considerably long period of time. The current spike and ringing disables normal operation of the circuit. Furthermore, these spurious components become noise components mixed in an output from the circuit. In addition to this disadvantage, an electromagnetic noise component is generated due to an abrupt current flow reversal. In other words, noise components are radiated in space in the form of radio waves. The current spike, ringing, and electromagnetic noise are decisive spurious components in preventing large current control in a high frequency region. This typically occurs in a semiconductor circuit such as a switching power supply circuit.

In order to eliminate the current spike, ringing and electromagnetic noise, a reactor is connected in series with a semiconductor device in the circuit. The reactor includes a core having a through hole in the vicinity of the center thereof and a conductor wound around the core through the through hole. The core is insulated from the conductor. A conventional reactor includes a ferrite or permalloy core. However, when a ferrite core is used, since a squareness ratio (Br/B.sub.1) and a saturated magnetic flux density are small, the operation of the core is degraded. In order to obtain efficient operation of the core, the core size must be increased. When a permalloy core is used, it has a high coercive force (Hc) which degrades the high frequency characteristics, resulting in inconvenience.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide an apparatus and a method for effectively preventing current spike, ringing and electromagnetic noise in a circuit containing a semiconductor device by the use of a reactor.

The core of the reactor of the present invention is made of an amorphous magnetic alloy which has B.sub.1 (a magnetic flux density in a magnetic field of 1 Oe) of 6 kilogauss or more, a coercive force (Hc) of 0.5 Oe or less, and a squareness ratio (Br/B.sub.1) (where Br is the residual magnetic flux density) of 0.8 or more when the frequency is set to be 100 kHz. The present invention provides for apparatus and a method of using a reactor for a circuit containing a semiconductor device, the reactor including: a core which has a through hole and which is made of an amorphous magnetic alloy which has B.sub.1 of 6 kilogauss or more, a coercive force of 0.5 Oe or less and a squareness ratio of 0.8 or more at a frequency of 100 kHz; and a conductor wound around the core through the through hole. The core is insulated from the conductor.

According to the present invention, a current spike, ringing, and electromagnetic noise can be effectively prevented. The apparatus and method of the present invention can be effectively used even in a high frequency region.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a reactor used in the method present invention; and

FIG. 2 is a circuit diagram of a circuit used for testing the performance of the reactor shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown in FIG. 1, a reactor 10 used in the present invention includes a core 12 having a through hole 14. The outer surface of the core 12 is coated with an insulator such as resin. A single conductor 16 is wound around the core 12 through the through hole 14. The conductor 16 is also coated with resin or the like. The external appearance of the reactor used in the present invention is the same as that of a conventional reactor, and a detailed description thereof will be omitted throughout the specification.

The core of the reactor used in the present invention is made of an amorphous magnetic alloy having a value for B.sub.1 of 6 kilogauss or more, a coercive force of 0.5 Oe or less and a squareness ratio of 0.8 or more at a frequency of 100 kHz. A preferred formula of the amorphous magnetic alloy is given as general formula (I) as follows:

Co.sub.a M.sub.b M'.sub.c Y.sub.d (I)

wherein M is at least one metal atom selected from the group consisting of iron and manganese, M' is a transition metal element (excluding iron and manganese), Y is at least one element selected from the group consisting of silicon, boron, phosphorus, carbon, germanium, zinc and aluminum, and a, b, c and d indicate atomic percent of the respective elements in the alloy so that a+b+c+d=100, and 50.ltoreq.a.ltoreq.80, 0.ltoreq.b.ltoreq.10, and 0.ltoreq.c.ltoreq.10. Preferred ranges of a, b, and c are 55.ltoreq.a.ltoreq.75, 2.ltoreq.b.ltoreq.8, 1.ltoreq.c.ltoreq.8. Preferred M' includes chromium, nickel, niobium, molybdenum, zirconium, tungsten, ruthenium, titanium, vanadium, tantalum, hafnium, rhenium, copper and yttrium. The element "M" in the above formula serves to reduce the magnetostriction of the amorphous alloy, so that it prevents the magnetic characteristics of the reactor from being degraded in a case where the reactor is covered with resin by molding the resin. The element "M'" in the above formula contributes to the improvement of the magnetic characteristics and the thermal stabilization of the amorphous alloy, so that it enables the reactor to be used for a long period without degrading its performance. The element "Y" in the above formula serves to make the alloy amorphous.

The core of the reactor according to the present invention can be prepared as follows. A molten metal is injected in the form of a thin film from a nozzle onto a cooled roller. By this operation an amorphous magnetic alloy ribbon having a thickness of about 10 to 50 .mu.m is prepared (single roll method). An insulating material such as magnesium oxide powder is applied to the ribbon, so that the ribbon is insulated. The insulated ribbon is wound around a proper core tube and the tube is pulled out, thus preparing the core of the reactor of the present invention. Alternatively, the central part of the amorphous magnetic alloy ribbon obtained as described above is punched. An insulating material such as magnesium oxide powder is applied to the resultant structure. The resultant ribbons are stacked to prepare a core. The single roll method for preparing an amorphous alloy is well-known to those skilled in the art, and a detailed description thereof will be omitted.

The resultant core is coated with a resin, and an insulated single conductor is wound around the core through the through hole of the core, thus obtaining the reactor which is used in the present invention.

This reactor is generally connected in series with a semiconductor device in a circuit. Thus, a current spike or the like generated from the semiconductor device can be reduced by the reactor.

EXAMPLE 1

An amorphous magnetic alloy ribbon of Co.sub.68 Fe.sub.3 Cr.sub.3 Si.sub.13 B.sub.13 was prepared by the single roll method. Magnesium oxide powder was applied to the ribbon. The insulated ribbon was wound around a quartz tube (having a diameter of 6 mm) for 20 turns. Thereafter, the quartz tube was removed from the wound ribbon, thus preparing a core. The core was coated with epoxy resin and was insulated. An insulated conductor was wound around the insulated core for 4 turns, thus preparing a reactor for use in the present invention.

As shown in FIG. 2, the resultant reactor 20 was connected in series with a diode 18 in a switching power supply circuit. Efficiency (percentage ratio of an output from a switching power supply to an input to a transformer in the circuit), a spike current, ringing, and high-frequency noise were measured when the frequency was set to be 100 kHz.

Furthermore, two insulated conductors were wound around the core, and an AC hysteresis curve at a frequency of 100 kHz was obtained by using an AC magnetic field measuring apparatus when an external magnetic field of 1 Oe was applied. According to this curve, B.sub.1, the coercive force and the squareness ratio were measured.

For the purpose of comparison, the same test was conducted for reactors respectively having cores of ferrite and Permalloy. Furthermore, the test was conducted to measure the spike current, ringing and high-frequency noise when the reactor was not used in the circuit containing the semiconductor device. The obtained results are shown in Table 1 below.

                TABLE 1                                                     

     ______________________________________                                    

     Without                 Ferrite    Permalloy                              

     reactor        Example  core       core                                   

     ______________________________________                                    

     Efficiency                                                                

             77         78       75       74                                   

     (%)                                                                       

     Spike   5.4        0.15     4.4      2.8                                  

     current (A)                                                               

     Ringing Significant                                                       

                        None     Significant                                   

                                          Small                                

     High-   0          -22      -3       -5                                   

     frequency                                                                 

     noise (dB)                                                                

     Remarks                              Reactor                              

                                          generated                            

                                          heat                                 

     B.sub.1 (KG)                                                              

             --         6.4      3.8      8.0                                  

     Coercive                                                                  

             --         0.42     0.62     1.2                                  

     force (Oe)                                                                

     Squareness                                                                

             --         0.85     0.75     0.90                                 

     ratio                                                                     

     ______________________________________
EXAMPLE 2

Amorphous magnetic alloy ribbons respectively having compositions shown in Table 2 were prepared by the single roll method. Each ribbon was wound to obtain a core having dimensions 7 mm.times.6 mm.times.4 mm and was heated at a temperature of 400.degree. C. for 30 minutes. B.sub.1, the coercive force and the squareness ratio were measured at a frequency of 100 kHz. The results are shown in Table 2.

The reactors were formed from these cores in the same manner as in Example 1. Each reactor was then arranged in the switching power supply circuit used in Example 1, and the efficiency was measured. The percentages in terms of efficiency of the reactors fell within the range between 78% and 80%. In this diode circuit, current spike and ringing did not occur, and normal circuit operation was obtained.

                TABLE 2                                                     

     ______________________________________                                    

                                            Br/B.sub.1                         

     No.  Composition       B.sub.1 (KG)                                       

                                     Hc (Oe)                                   

                                            (%)                                

     ______________________________________                                    

     1    Co.sub.67 Fe.sub.5 Ni.sub.3 Si.sub.10 B.sub.15                       

                            7.0      0.31   97.2                               

     2    Co.sub.68 Fe.sub.4 Nb.sub.2 Si.sub.13 B.sub.13                       

                            7.2      0.34   96.8                               

     3    Co.sub.71 Fe.sub.2 Mn.sub.4 Si.sub.14 B.sub.9                        

                            7.5      0.35   98.0                               

     4    Co.sub.70 Fe.sub.3 Mo.sub.2 Ti.sub.1 Ge.sub.9 B.sub.15               

                            7.2      0.32   97.0                               

     5    Co.sub.68 Fe.sub.5 Zr.sub.3 Nb.sub.2 Si.sub.10 B.sub.10 C.sub.2      

                            7.4      0.34   97.5                               

     6    Co.sub.66 Fe.sub.5 W.sub.5 Si.sub.11 B.sub.11 Sn.sub.2               

                            6.8      0.30   96.8                               

     7    Co.sub.66 Fe.sub.4 Ru.sub.2 Si.sub.10 B.sub.18                       

                            6.3      0.27   96.8                               

     ______________________________________

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is understood that the invention is not to be limited to the disclosed embodiment but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures.

Claims

1. A method of restraining current spikes, ringing, and electromagnetic noise in an electric circuit that includes a semiconductor device, the current spikes, ringing and electromagnetic noise being of a type that occurs when a voltage applied to the semiconductor device is inverted, said method comprising the step of:

providing a reactor in series with said semiconductor device, wherein the reactor includes (a) a core formed with a through hole and which is made of an amorphous magnetic alloy having a magnetic flux density of not less than 6 kilogauss at an external magnetic field of 1 oersted, a coercive force of not more than 0.5 oersted, and a squareness ratio of not less than 0.8 when a frequency of said circuit is set to approximately 100 kilohertz, and (b) a conductor wound around the core through the through hole, the conductor being insulated from the core, wherein said amorphous magnetic alloy has a general formula:

2. A circuit, comprising:

a semiconductor device; and
reactor means, coupled in series with said semiconductor device, for restraining current spikes, ringing, and electromagnetic noise in said circuit, said reactor means including a core which has a through hole and which is made of an amorphous magnetic alloy having a magnetic flux density of not less than 6 kilogauss at an external magnetic field of 1 oersted, a coercive force of not more than 0.5 oersted, and a squareness ratio of not less than 0.8 when a frequency of said circuit is set to approximately 100 kilohertz, wherein said amorphous magnetic alloy has a general formula:

3. A method according to claim 1, wherein said M' is one element selected from the group consisting of chrominum, nickel, niobium, molybdenum, zirconium, tungsten, ruthenium, titanium, vanadium, tantalum, hafnium, rhenium, copper and yttrium.

4. A method according to claim 1, wherein said a, b, c range 55.ltoreq.a.ltoreq.75, 2.ltoreq.b.ltoreq.8, and 1.ltoreq.c.ltoreq.8, respectively.

5. A circuit according to claim 2 wherein said M' is one element selected from the group consisting of chromium, nickel, niobium, molybdenum, zirconium, tungsten, ruthenium, titanium, vanadium, tantalum, hafnium, rhenium, copper and yttrium.

6. A circuit according to claim 2 wherein said a, b, and c range 55.ltoreq.a.ltoreq.75, 2.ltoreq.b.ltoreq.8, and 1.ltoreq.c.ltoreq.8, respectively.

7. A circuit having reduced current spikes, ringing, and electromagnetic noise, comprising:

a semiconductor device; and
a reactor connected in series with said semiconductor device, said reactor including: (a) a core having a through hole and made of an amorphous magnetic alloy having a magnetic flux density of not less than 6 kilogauss at an external magnetic field of 1 oersted, a coercive force of not more than 0.5 oersted, and a squareness ratio of not less than 0.8 when a frequency of said circuit is set to approximately 100 kilohertz, wherein said amorphous magnetic alloy has a general formula consisting essentially of:

8. A circuit according to claim 7 wherein said reactor further includes a conductor wound around said core through said through hole, said conductor being insulated from said core.

9. A circuit according to claim 7, wherein said M' is one element selected from the group consisting of chromium, nickel, niobium, molybdenum, zirconium, tungsten, ruthenium, titanium, vanadium, tantalum, hafnium, rhenium, copper and yttrium.

10. A circuit according to claim 7 wherein said a, b and c range 55.ltoreq.a.ltoreq.75, 2.ltoreq.b.ltoreq.8, and 1.ltoreq.c.ltoreq.8, respectively.

11. A method according to claim 1, wherein said electromagnetic noise is at least -22 dB.

12. A method according to claim 11, wherein said electromagnetic noise is substantially -22 dB.

13. A method according to claim 1, wherein said current spikes are at least 0.15 A/4 turns of a coil of said reactor.

14. A method according to claim 13, wherein said spike currents are substantially 0.15 A/4 turns of a coil of said reactor.

15. An apparatus according to claim 2, wherein said electromagnetic noise is at least -22 dB.

16. An apparatus according to claim 15, wherein said electromagnetic noise is substantially -22 dB.

17. An apparatus according to claim 2, wherein said current spikes are at least 0.15 A/4 turns of a coil of said reactor.

18. An apparatus according to claim 17 wherein said current spikes are substantially 0.15 A/4 turns of said coil.

19. A method as in claim 1 wherein there is only one conductor wound on said core.

Referenced Cited
U.S. Patent Documents
4221592 September 9, 1980 Ray
4262233 April 14, 1981 Becker et al.
4314594 February 9, 1982 Pfeifer et al.
4363067 December 7, 1982 Radomski
4411716 October 25, 1983 Shiiki et al.
4420348 December 13, 1983 Shiiki et al.
4424459 January 3, 1984 Inomata et al.
4439253 March 27, 1984 Ramanan
4451876 May 29, 1984 Ogata
Foreign Patent Documents
086485 February 1983 EPX
0072574 February 1983 EPX
2708151 September 1977 DEX
2806052 November 1978 DEX
2855858 July 1979 DEX
2824749 December 1979 DEX
3021536 December 1980 DEX
2924280 January 1981 DEX
2317370 November 1975 FRX
7512294 October 1975 NLX
7807836 July 1978 NLX
424425 February 1935 GBX
Other references
  • Patent Abstracts of Japan, vol. 6, No. 164 (E-127)(1042), 27 Aug. 1982, blz. 1042 E127 & JP.-A-57-83-005, (Hitachi Kinzoku) (24-05-1982). Proceedings of Powercon 8, Dallas, Texas, Apr. 27-30, 1981. Elektronik, No. 3, 1981, pp. 43-50, Induktive Bauelemente der Leistungselektronik, Karl-Heinz Bretthauer et al. Technical Communication, Krupp Research Reports, vol. 40, 1982, Amorphe Metalle-Weichmagnetische Werkstoffe Mit Zukunft-W. Jaschinski.
Patent History
Patent number: 4745536
Type: Grant
Filed: Dec 1, 1986
Date of Patent: May 17, 1988
Assignee: Tokyo Shibaura Denki Kabushiki Kaisha (Kawasaki)
Inventors: Yorio Hirose (Tokyo), Yasunobu Sakamizu (Tokyo)
Primary Examiner: Patrick R. Salce
Assistant Examiner: Judson H. Jones
Law Firm: Cushman, Darby & Cushman
Application Number: 6/936,934
Classifications
Current U.S. Class: 363/21; With Means To Introduce Or Eliminate Frequency Components (363/39); Semiconductor Type (363/53)
International Classification: H02M 3335;